1975–1976 Triumph Trident T160 Electric Start Workshop Manual

This workshop manual covers the 1975–1976 Triumph Trident T160 with the 750cc three-cylinder engine and electric starter, from engine number 00101. Compiled by John R. Nelson and published by J.R. Technical Publications in April 1982, it incorporates technical material contributed by former factory staff.

Search, bookmarks, and diagram detail: OCR text supports searches across the service chapters, with 50 embedded bookmarks for main sections and selected subsections. Recognition of diagram labels is incomplete. Small wiring labels need zooming, and some crowded wire-color codes remain difficult to read.

• Engine repair: Engine removal, cylinder-head overhaul, valve-seat cutting, piston and bore inspection, crankcase disassembly, crankshaft servicing, and main-bearing replacement.

• Primary drive and gearbox: Diaphragm-spring clutch service, shock-absorber rubber replacement, sprocket alignment, gear-cluster overhaul, and gearshift cross-shaft and kickstart repair.

• Carburetors and lubrication: Amal 626 carburetor disassembly, triple-carburetor synchronization, scheduled oil and filter service, oil-pressure checks, oil-pump removal, and oil-cooler servicing.

• Brakes and wheels: Lockheed hydraulic brake overhaul, front and rear bleeding procedures, wheel-bearing replacement, alignment, balancing, and specialist wheel-building guidance.

• Forks and chassis: Telescopic fork disassembly, seal replacement, steering-head bearing service, Girling rear suspension inspection, swingarm-bushing replacement, and frame-alignment checks.

• Electrical diagnosis: Lucas ignition, charging, and starter troubleshooting; 7CA contact-breaker adjustment; static and stroboscopic ignition timing; wiring diagrams and component tests.

It was written for Trident owners undertaking maintenance, overhaul, and repair, while the wheel-building section is expressly intended for specialists.

Engine Repair and Reference Data

General data supplies valve clearances, fluid capacities, torque settings in lb-ft and kg-m, and standard/undersize dimensions for big-end and center-main journals. Rebuild coverage includes rebore tables, connecting-rod bolt-stretch checks, and the cylinder-head tightening sequence.

Piston variants: The manual distinguishes 9.5:1 pistons from the 8.5:1 version identified by an “L” stamped on the front engine lug.

The cylinder-block section warns that scratching the connecting rods can lead to fatigue failure.

Primary Drive and Gearbox

The primary-drive chapter covers the single-plate clutch and explains why sprocket alignment must account for shock-absorber end float. Five-speed constant-mesh gearbox coverage extends to selector-fork and camplate inspection, mainshaft and layshaft bearings, and the left-footshift cross-shaft mechanism.

Amal Carburetors and Dry-Sump Lubrication

The exploded carburetor view accompanies throttle-slide synchronization, pilot-mixture, choke-cable, and idle adjustments. The engine lubrication diagram traces feed and return paths through the duplex pump and oil cooler.

Oil-pressure diagnosis includes the relief and anti-drain valves. The full-flow filter section warns that reversed installation cuts off the oil supply, risking engine damage.

Lockheed Brakes, Wheels, and Suspension

The hydraulic flow diagram accompanies master-cylinder and caliper repair. A dedicated rear-brake bleeding note addresses trapped air; wheel-building guidance includes spoke details and rim-offset dimensions.

The introduction also identifies the disc-brake information as useful for certain later T150 and Rocket 3 models. The main coverage remains the T160.

The sectional view of the assembled fork leg explains hydraulic damping. Rear suspension coverage addresses Girling spring removal and inspection of sealed hydraulic dampers.

Keep the machine securely supported on a level surface during heavy dismantling or hydraulic brake work.

Lucas Electrical Troubleshooting

The starter section distinguishes a motor that will not operate from one that cranks slowly, with continuity and voltage-drop tests for the relay, solenoid, cables, and grounds. Those tests help isolate a starting fault before replacing the motor.

Charging diagnosis covers the alternator, rectifier, and Zener diode. The wiring diagram identifies the optional 2MC capacitor and North American headlight warning unit within the positive-ground system. An exploded electric-starter mechanism view supports component identification.

Service Tools and Conversion Tables

Illustrated service tools include the 61-6063 valve-guide tool and 60-1860 clutch-hub extractor, with superseding numbers where listed. Reference charts cover metric/inch conversions, drill sizes, wire gauges, and British and Unified threads.

PDF Contents and Page Breakdown

The single printable, English-language file is a 198-page PDF: 10 front-matter and photograph pages, 180 technical/reference pages, seven blank pages, and one final printer’s page with added starter-relay connection notes. The two supplementary photograph pages are included in the front matter; all additional pages are already counted in the total.